Portable pressure switch calibration and diagnostic tool

ABSTRACT

An apparatus for calibration and testing of pressure switches which are used in residential and commercial HVAC systems. The apparatus can be used to test, set, or adjust a pressure switch or a pressure signal transducer to the manufacturer&#39;s specifications. The apparatus includes an exterior housing with an on/off switch and at least one vacuum inlet nozzle, and the inside of the housing includes an air compressor to which the amount of voltage supplied can be manually controlled. The air compressor typically operates from a battery power supply located within the housing. A pressure measuring device, such as a differential pressure gage, and a conductivity indicator are typically used in conjunction with the device to calibrate adjustable pressure switches and to test and diagnose faulty pressure switches. The apparatus can include the pressure measuring device and/or the conductivity indicator within its housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 14/175,188 filed Feb. 7, 2014, the disclosure of which isincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to testing and calibration ofpressure switches, and more particularly, to an improved portable,hand-held tool for calibrating and diagnosing problems with pressureswitches associated with HVAC systems.

BACKGROUND OF THE INVENTION

A pressure switch is a mechanical device which converts a pressurechange of a liquid or gas into an electrical function. The pressurechange might be measured as pressure, vacuum, or differential betweentwo pressure inputs. In every case, the pressure switch will employ adiaphragm, a piston, a signal transducer, or other pressure-responsivesensor which is coupled to the mechanical means of actuating a switch.Pressure switches fulfill a variety of monitoring and controlapplications, and they are employed in virtually every industry, fromappliances to automobiles to computers. They are often used in pneumaticsystems, such as air compressor pressure switches for furnaces or HVACsystems, as well as water pressure switches or oil pressure switches.Pressure switches are common components of high-efficiency heatingsystems as well as high-efficiency water heaters. Different manufacturesmake differing types of pressure switches, and each type is setaccording to the manufacturer's specifications.

Pressure switches activate electromechanical or solid-state switchesupon reaching a specific pressure level. For example, “normally open”pressure switches are used to keep the system from operating should thepressure not be high enough or exceed the safety limit. For example,should a flue become partially plugged, the pressure in the exhaust willbuild up presenting a dangerous condition. Flue gases containing carbonmonoxide will spill into the living space. The flames will becomeunstable and “float” or “spill” out of the heat exchanger creating afire hazard. Under these conditions, the normally-open switch will notclose and the furnace will not be able to run. As this exampleillustrates, if the pressure in a system becomes either too high or toolow, depending on whether the switch is a positive pressure switch thatmeasures positive pressures, or a negative pressure switch that measuresnegative (vacuum) pressures, the pressure-responsive sensor (e.g., adiaphragm within the switch) will be affected to the point where thepressure switch will not complete the circuit, such that the power tothe system controls is lost and the system does not run. In contrast,“normally closed” switches can also be used to verify that it is safefor the furnace to come on. If the switch had failed and it was stuckopen, then the furnace would not come on.

Dual, or differential, pressure switches have a normally closed and anormally open circuit. The normally closed circuit allows the furnace tosafely initiate the sequence of operation resulting in a flame.Typically negative pressure is created by the expelling of the fluegases, and the normally open circuit will close. This allows the furnaceto continue operating safely because the flue gases are being expelled.Most differential pressure switches have two hoses connected. The firsthose is located at the vacuum side of the switch and is connected to theflue circuit (the flue circuit expels the burned gases). The second hoseis located at the positive pressure side of the switch and is connectedto the gas valve (the gas circuit mixes air with the gas creating theflame). Generally, there should be little or no positive pressure.Should a positive pressure exist, it is typically an indication that theprimary or secondary heat exchanger is becoming plugged. As a result,pressure build up creates a positive pressure which will negate from thenegative or vacuum pressure, thus causing the negative (vacuum) pressureto drop below the setting and shut the furnace down. Dual pressureswitches are also used to set the gas pressure of the gas valve in highefficiency units. When the gas ignites there is a slight variance in thepressures measured by a manometer. The gas pressure is then adjusted tothe manufacturer's specifications.

Faulty pressure switches may be one of the most misdiagnosed problems intoday's modern furnaces. Many pressure switches have been replacedneedlessly, simply because there was no proper way to test them. It istypically the technician's best guess as to whether a problem existswhich necessitates replacement of the pressure switch. Thus, manyservice calls could have been resolved easily if the pressure switch wasfirst able to be tested properly before being replaced. A servicetechnician using a pressure-measuring device such as a manometer cantest “static pressure” in the line to see if there is enough pressure toclose the switch, but this will not reveal whether or not the pressureswitch itself is working properly.

In light of this, a significant need exists in the HVAC field for thediagnosis and calibration of pressure switches. Pressure switches are“safety devices” in today's modern heating systems. These safety devicesshut the heating system down should there be a problem with expellingthe flue gas which contains carbon monoxide. They also insure that thesystem is getting enough fresh air for the correct and safe combustionof the fuel gas mixture. Since pressure switches are safety devices usedon all high-efficiency heating systems used for heating residential,commercial and industrial buildings, it is extremely important that anymalfunction of a pressure switch is properly diagnosed, and, if it is anadjustable pressure switch, that it is set correctly.

Prior art calibration devices also do not allow one to accuratelydiagnose pressure switch failure, or impending failure. Often theservice technician must simply guess if a pressure switch has failed, orelse guess the remaining life expectancy of a pressure switch byexchanging the pressure switch to see if the replacement switchcorrected the problem. U.S. Pat. No. 7,441,439 to the present inventorMcFarland, which is incorporated herein by reference in its entirety,teaches a portable pressure switch tool that can be used to createpressure or vacuum in order to test, set or adjust a pressure switch tothe manufacturer's specifications while in the field. Prior to the '439patent to McFarland, it was not possible to accurately diagnose earlyfailure or possible failure of a pressure switch that was starting to gobad. Even worse, technicians have wasted valuable time being called backto a worksite after replacing a pressure switch, only to find out thatthe problem was the flue, or a blocked intake or condensate system.

While the '439 patent to McFarland teaches a device that is useful forcreating pressure or vacuum in order to test, set, or adjust a pressureswitch to the manufacturer's specifications while in the field, thedevice includes manual control valves for adjusting the vacuum. Thistypically requires the use of both hands in order to operate the device.Therefore, there exists a need for an HVAC service technician to be ableto quickly, easily and accurately set and/or calibrate adjustablepressure switches in an HVAC system without having to operate manualcontrol valves. It would also be advantageous to provide a hand-heldcalibration and diagnostic tool that can be used on pressure switcheswithout having to use both hands to operate manual control valves. Theseand other features and advantages of the present invention will becomemore apparent with reference to the accompanying specification andclaims.

SUMMARY OF THE INVENTION

In general, the present invention is an apparatus for calibration andtesting of residential and commercial HVAC system pressure switches. Theapparatus creates a controlled vacuum for testing the pressure switches,so technicians can tell exactly when a pressure switch closes and opens.This either proves that the switch is within specification, oridentifies if the switch is starting to fail.

A first aspect of the invention provides an apparatus for calibratingand testing a pressure switch, the apparatus comprising: (a) an aircompressor having a vacuum-side inlet and a pressure-side outlet; (b) atleast one vacuum inlet nozzle in fluid communication with thevacuum-side inlet of the air compressor, the at least one vacuum inletnozzle being located on the external surface of the housing; (c) apositive pressure outlet nozzle in fluid communication with thepressure-side outlet of the air compressor; (d) a circuit board locatedon the inside of the housing (e) a battery located on the inside of thehousing for supplying power to the circuit board; (f) an increasevoltage button located on the external surface of the housing and inelectrical communication with the circuit board, wherein activating theincrease voltage button will cause the circuit board to increase thevoltage supplied to the compressor pump; (g) a decrease voltage buttonlocated on the external surface of the housing and in electricalcommunication with the circuit board, wherein activating the decreasevoltage button will cause the circuit board to decrease the voltagesupplied to the compressor pump; (h) a pair of conductivity indicatorlead inputs located on the external surface of the housing and inelectrical communication with the circuit board; (i) a conductivityindicator light located on the external surface of the housing and inelectrical communication with the circuit board, wherein theconductivity indicator light is operable to visually indicate whetherthe pressure switch is open or closed; and (j) an on/off button locatedon the external surface of the housing for completing an electricalcircuit between the battery and the circuit board, wherein when theon/off button is placed in the “on” position, the circuit is completedand the battery, the air compressor, the increase and decrease voltagebuttons, and the conductivity indicator light are operational.

Another aspect of the invention provides an apparatus for calibratingand testing a pressure switch, the apparatus comprising: (a) a housingincluding an inside and an external surface; (h) an air compressorlocated on the inside of the housing, the air compressor including avacuum-side inlet and a pressure-side outlet; (c) a first vacuum inletnozzle located in the external surface of the housing, the first vacuuminlet nozzle being in fluid communication with the vacuum-side inlet ofthe air compressor; (d) a second vacuum inlet nozzle located in theexternal surface of the housing, the second vacuum inlet nozzle being influid communication with the vacuum-side inlet of the air compressor;(e) a positive pressure outlet nozzle in fluid communication with thepressure-side outlet of the air compressor, wherein the positivepressure outlet nozzle is located inside the housing of the apparatus;(f) a circuit board located on the inside of the housing; (g) a batterylocated on the inside of the housing for supplying power to the circuitboard; (h) an increase voltage button located on the external surface ofthe housing and in electrical communication with the circuit board,wherein activating the increase voltage button will cause the circuitboard to increase the voltage supplied to the compressor pump; (i) adecrease voltage button located on the external surface of the housingand in electrical communication with the circuit board, whereinactivating the decrease voltage button will cause the circuit board todecrease the voltage supplied to the compressor pump; (i) a pair ofconductivity indicator lead inputs located on the external surface ofthe housing and in electrical communication with the circuit board; (k)a conductivity indicator light located on the external surface of thehousing and in electrical communication with the circuit board, whereinthe conductivity indicator light is operable to visually indicatewhether the pressure switch is open or closed; and (l) an on/off buttonlocated on the external surface of the housing for completing anelectrical circuit between the battery and the circuit board, whereinwhen the on/off button is placed in the “on” position, the circuit iscompleted and the battery, the air compressor, the increase and decreasevoltage buttons, and the conductivity indicator light are operational.

Another aspect of the invention provides an apparatus for calibratingand testing a pressure switch, the apparatus comprising: (a) a housingincluding an inside and an external surface; (b) an air compressorlocated on the inside of the housing, the air compressor including avacuum-side inlet and a pressure-side outlet; (c) a vacuum inlet nozzlelocated in the external surface of the housing, the vacuum inlet nozzlebeing in fluid communication with the vacuum-side inlet of the aircompressor; (d) a positive pressure outlet nozzle in fluid communicationwith the pressure-side outlet of the air compressor; (e) a circuit boardlocated on the inside of the housing; (t) a battery located on theinside of the housing for supplying power to the circuit board; (g) anincrease voltage button located on the external surface of the housingand in electrical communication with the circuit board, whereinactivating the increase voltage button will cause the circuit board toincrease the voltage supplied to the compressor pump; (h) a decreasevoltage button located on the external surface of the housing and inelectrical communication with the circuit board, wherein activating thedecrease voltage button will cause the circuit board to decrease thevoltage supplied to the compressor pump; (i) a pair of conductivityindicator lead inputs located on the external surface of the housing andin electrical communication with the circuit board; (j) a conductivityindicator light located on the external surface of the housing and inelectrical communication with the circuit board, wherein theconductivity indicator light is operable to visually indicate whetherthe pressure switch is open or closed; (k) a pressure measuring nozzlelocated on the external surface of the housing; (l) a pressure measuringdevice located on the inside of the housing and being in fluidcommunication with the pressure measuring nozzle for measuring theamount of pressure communicated through the pressure measuring nozzle;(m) a pressure readout screen located on the external surface of thehousing and in electrical communication with the circuit board and thepressure measuring device, wherein the pressure readout screen isoperable to visually indicate the amount of pressure being measured bythe pressure measuring device; and (n) an on/off button located on theexternal surface of the housing for completing an electrical circuitbetween the battery and the circuit board, wherein when the on/offbutton is placed in the “on” position, the circuit is completed and thebattery, the air compressor, the increase and decrease voltage buttons,the pressure measuring device, and the conductivity indicator light areoperational.

The calibration/diagnostic apparatus of the present invention providesvacuum and air pressure by means of a small battery-powered aircompressor located inside its housing, which is controlled by amicrochip circuit board, as is known in the art. In one embodiment, aconductivity indicator is incorporated within the housing of theapparatus and the apparatus is typically associated with a free-standingpressure test means that is removably attachable to the apparatus. Inanother embodiment, both the pressure test means and conductivityindicator are incorporated within the housing of the apparatus.

The nature and advantages of the present invention will be more fullyappreciated from the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments of the invention and,together with a general description of the invention given above, andthe detailed description given below, serve to explain the principles ofthe invention.

FIG. 1 is a schematic view of a prior art embodiment of a portablecalibration apparatus, connected to a pressure switch.

FIG. 2 is a schematic view of the interior air pressure circuitry of theprior art portable calibration apparatus of FIG. 1.

FIG. 3 is a plan view of the interior air pressure circuitry of theprior art portable calibration apparatus of FIG. 1.

FIG. 4 is a plan view of the interior electrical circuitry of the priorart portable calibration apparatus of FIG. 1.

FIG. 5 is a schematic view of one embodiment of a portable calibrationapparatus according to the present invention, connected to a pressureswitch and an external manometer.

FIG. 6 is a schematic view of the interior air pressure circuitry of theportable calibration apparatus of FIG. 5.

FIG. 7 is a plan view of the interior air pressure circuitry of theportable calibration apparatus of FIG. 5.

FIG. 8 is a plan view of the interior electrical circuitry of theportable calibration apparatus of FIG. 5.

FIG. 9 is a schematic view of another embodiment of a portablecalibration and test tool of the invention connected to a pressureswitch, in which both a pressure test means and conductivity indicatorare incorporated within the housing of the apparatus.

FIG. 10 is a plan view of the interior air pressure circuitry of theapparatus of FIG. 9.

FIG. 11 is a plan view of the interior electrical circuitry of theapparatus of FIG. 9.

FIG. 12 is a plan view of the connection between the apparatus of FIG. 9and the pressure switch, showing an external bleed port that can beadded for achieving low pressures.

FIG. 13 is a plan view of the interior air pressure circuitry of oneembodiment of a portable calibration apparatus according to the presentinvention.

FIG. 14 is a plan view of the interior electrical circuitry of theportable calibration apparatus of FIG. 13.

DETAILED DESCRIPTION OF THE INVENTION

Definitions:

As defined herein, an “air pressure measuring device” is a tool foraccurate measurement of air pressure. With the present invention, thistool is used to measure the pressure being transmitted from theinventive apparatus to a pressure switch. Typically, an air pressuremeasuring device can measure absolute pressure, typically in pressureunits of “inches of water,” For example, a Ailagnehelic gage (such asone manufactured by Dwyer), a differential pressure manometer, a digitalmanometer, or equivalent pressure gage have all been found particularlysuitable as an air pressure measuring device for the invention.

A “circuit board” is an insulated board on which interconnected circuitsand components such as microchips are mounted or etched. The circuitboard controls the sequence of events needed for proper operation of theapparatus of the invention, including the control and distribution ofpower to the various electronic components.

“Electrical components” are any elements of the apparatus that run orare powered by electricity. Typically the electrical components of thepresent invention include, but are not limited to, a circuit board, anair compressor, a battery, an increase voltage button, a decreasevoltage button, conductivity indicator lead inputs, a conductivityindicator light, and an on/off button.

A “conductivity indicator” is generally an electrical measuring deviceused to test whether an adjustable pressure switch is open or closed.Typically the conductivity indicator of the present invention includes apair of test leads lead inputs) and a light.

A “pressure test means” is the combination of an air pressure measuringdevice and a connecting means such as a flexible hose or tubing.

The present invention is a calibration and diagnostic apparatus for usewith pressure switches that are typically used in HVAC systems andresidential and commercial furnaces. The apparatus is able to calibrateadjustable pressure switches to manufacturers' specifications. Whilesaving contractors from carrying a large inventory of pressure switcheson their trucks and from having to leave the job site to buypre-calibrated switches.

While U.S. Pat. No. 7,441,439 to McFarland (the present inventor), whichis incorporated herein by reference in its entirety, discloses the useof a recirculation circuit 203 and a manual control valve 18 to regulatethe vacuum strength (see prior art FIGS. 1-4), the present inventionimproves upon this and regulates the vacuum strength by controlling theamount of voltage supplied to the air compressor pump (see FIGS. 5-14),thereby allowing a user to regulate the strength of the pump vacuumwithout the need of a recirculation circuit 203 or a manual controlvalve 18. Specifically, the amount of voltage supplied to the aircompressor pump is controlled by pressing an “up arrow” button 60 or a“down arrow” button 62 on the external surface of the apparatus housing(see, e.g. FIG. 5). By directly controlling the speed of the motor onthe air compressor pump with the down and up buttons rather than acontrol valve, the user can change the vacuum strength and performtests, as needed, without the need for any other instrument, and withouthaving to use both hands in order to hold the apparatus and operate anadjustable control valve. The technician thus has more precise controlof the vacuum created in order to close and open the pressure switchbeing tested, and is typically able to perform the tests with one hand,with all of the important information (e.g. from a circuit board andmanometer) in front of him. The present invention thus provides a fullyelectronic tool that eliminates the need for a manual control valve.

In the following Figures, positive and negative symbols are used forboth pressure and electricity. Thus, for clarity sake, positive andnegative pressure outlets will be indicated with [+] and [−],respectively, while positive and negative electrical poles will beindicated with (+) and (−), respectively, in the Figures.

With reference to FIG. 1, a prior art embodiment of a pressure switchcalibration and diagnostic apparatus is illustrated, which incorporatesa conductivity indicator 174 within the housing of the unit. Theapparatus 100 includes an on/off button 12 on the top of the housing, afirst vacuum inlet nozzle 14, and a bypass control valve 18. The bypasscontrol valve 18 is typically a needle valve with an external controlknob, and is capable of providing fine regulation of airflow. Theexternal surface of the housing 20 further includes a second vacuuminlet nozzle 114, a conductivity indicator light 174, and conductivityindicator lead inputs 176 and 178. As illustrated, the first vacuuminlet nozzle 14 can be removably connected to the pressure switch 22 byway of flexible hose 26. The pressure switch 22 is also connected toconductivity indicator leads 176 and 178 by electrical test leads 132and 133. When this circuit is completed, the conductivity indicatorlight 174 illuminates. As illustrated, either vacuum inlet nozzle 14 or114 of the apparatus 100 is removably connectable to an externalpressure measuring device 24 (such as a manometer) by way of flexiblehose 27.

FIGS. 2 and 3 illustrate a schematic and plan view, respectively, of theinternal air pressure circuitry of the prior art apparatus of FIG. 1.Specifically, FIG. 2 shows the air compressor 34 with a vacuum inlet 36and a pressure outlet 38 connected in fluid communication by flexibletubing 260, 261, 263, 124 and 126, and T-pieces 280A and 128 to thefirst vacuum inlet nozzle 14 and the second vacuum inlet nozzle 114. Arecirculation circuit 203 is created by flexible tubing 201, 202 runningfrom T-pieces 280A and 280B to the bypass control valve 18. Positivepressure flows freely from the unused internal positive pressure openingof T-piece 280A into the inside of the apparatus. Also, T-piece 128serves to divide the vacuum pressure generated by the compressor 34 intotwo parts, leading via flexible tubing 124 and 126 to the first vacuuminlet nozzle 14 and the second vacuum inlet nozzle 114, respectively.

FIG. 3 illustrates the air circuitry of the prior art apparatus of FIG.2 when assembled within the housing 20. Viewing either FIG. 2 or FIG. 3,when the air compressor 34 is in the “on” position, gas or air is drawninto the vacuum-side inlet 36, which reduces the air pressure on thevacuum-side connecting means 261. In a closed system, a vacuum iscreated. The reduced pressure at the vacuum inlet 36 is communicated viathe connecting means 261 and 263 and T-piece 280B to the first andsecond vacuum inlet nozzles 14, 114, to pull or draw air into thenozzles. Likewise, positive pressure is created by the compressor 34 asgas or air is pumped out of the pressure outlet 38, and is communicatedto the unused opening of the T-piece 280A, i.e. an internal positivepressure opening, to expel compressed air harmlessly within the insideof the housing 20.

The negative pressures at the nozzles 14, 114 are regulated byincreasing or decreasing the amount of air being circulated through therecirculation circuit 203. The bypass control valve 18 performs thisfunction. When the bypass control valve 18 is closed, the recirculationcircuit 203 is closed and there is no connection between the pressurecircuitry and the vacuum circuitry. This enables the compressor 34 toachieve maximum vacuum and pressure exerted at the nozzles 14, 114. Whenthe bypass control valve 18 is opened, then a portion of the flow of gasfrom the pressure-side outlet 38 of the air compressor 34 can bere-circulated back to the vacuum-side inlet 36 through the recirculationcircuit 203 via the flexible tubing 201 and 202 and T-pieces 280A and280B, leading to and away from the valve 18. Increased air recirculationdecreases the vacuum pressures at nozzles 14 and 114. Thus, the mass airflow entering the first and second vacuum inlet nozzles 14, 114, and themass air flow of air exiting the T-piece 280A, is regulated by means ofthe bypass control valve 18. Adjusting this valve 18 permits the user tocontrol the vacuum pressure at the first and second vacuum inlet nozzles14, 114, and to both test and calibrate pressure switches. The bypasscontrol valve 18 thus prevents undue stress on the air compressor bycontrolling the amount of air re-circulating through the recirculationcircuit, and controls the amount of air to be pulled in from the vacuumport 42.

FIG. 4 is a schematic view of the interior electrical circuitry of theprior art apparatus 100 of FIG. 1, and includes a battery 40 whichprovides electrical power to the air compressor 34. The positive pole(+) of the battery 40 is connected to one pole of the on/off button 12,and the negative pole (−) of the battery 40 is connected to both thenegative pole (−) of the air compressor 34 and the negative pole (−) ofthe conductivity indicator 174. The positive pole (+) of the aircompressor 34 is connected to another pole of the on/off button 12, suchthat when the on/off button is placed in the “on” position, the circuitis completed and the air compressor is operated. Turning the on/offbutton to the “off” position will break the circuit and the aircompressor 34 will turn off. For simplicity sake, the air pressurecircuitry of FIGS. 2 and 3 is shown separately from the electricalcircuitry of FIG. 4; however, both of these circuitries are housedtogether within housing 20 of this prior art apparatus 100.

In FIGS. 5-8, like numbers are used to indicate like parts as shown inthe prior art embodiment illustrated in FIGS. 1-4. With reference now toFIG. 5, an alternative embodiment 200 of the pressure switch calibrationand diagnostic apparatus of the present invention is illustrated.Similar to the apparatus 100 in FIGS. 1-4, this embodiment incorporatesa conductivity indicator 174 within the inside of the housing of theunit, and thus provides the service technician the ability to testpressure switches without having to use an external conductivityindicator. The apparatus 200 also includes an on/off button 13 which hasbeen moved to the center face of the housing 30 (compared to the button12 at the top of the housing in FIGS. 1-4), as well as a first vacuuminlet nozzle 14, a second vacuum inlet nozzle 114, an “up” arrow orincrease voltage button 60, a “down” arrow or decrease voltage button 62conductivity indicator light 174, and conductivity indicator lead inputs176 and 178 in the external surface of the housing 30. Unlike the priorart embodiment of FIGS. 1-4, there is no need for a bypass control valve18 or any interior recirculation circuit 203 (see FIG. 2). Pressing theincrease voltage button 60 will increase the voltage supplied to, andthus the speed and the induced vacuum created by the compressor pump,while pressing the decrease voltage button 62 will do the opposite,ultimately decreasing the induced vacuum.

As illustrated in FIG. 5, the first vacuum inlet nozzle 14 can beremovably connected to the vacuum port 42 of pressure switch 22 by wayof flexible hose 26. The pressure switch 22 is also connected toconductivity indicator leads 176 and 178 by electrical test leads 132and 133. When this circuit is completed, the conductivity indicatorlight 174 illuminates. As illustrated, either vacuum inlet nozzle 14 or114 of the apparatus 100 is removably connectable to an externalpressure measuring device 24, such as a manometer or magnehelic gage, byway of flexible hose 27.

FIGS. 6 and 7 illustrate a schematic and plan view respectively, of theinternal air pressure circuitry of device of FIG. 5. Specifically, FIG.6 shows an air compressor 234 with a vacuum inlet 36 and a pressureoutlet 38. T-piece 128 serves to divide the vacuum pressure generated atthe vacuum inlet 36 of the compressor 34 into two parts. Specifically,vacuum pressure is passed through flexible tubing 261 and splits atT-piece 128 to flexible tubing 124 and the first vacuum inlet nozzle 14,as well as from T-piece 128 to flexible tubing 126 and the second vacuuminlet nozzle 114. Significantly, it can be appreciated that therecirculation circuit 203 and the manual control valve 18 of theapparatus of FIG. 2 is not present in the improved apparatus of FIG. 6.Also, positive pressure flows freely inside the housing, typically fromflexible tubing 260 attached to the unused internal positive pressureoutlet 38.

FIG. 7 illustrates the air circuitry shown in FIG. 6 when assembledwithin the housing 30 of the apparatus 200. Viewing either FIG. 6 orFIG. 7, when the air compressor 234 is in the “on” position, gas or airis drawn into the vacuum-side inlet 36 which reduces the air pressure onthe vacuum-side connecting means 261. In a closed system, the vacuumcreated at the vacuum inlet 36 is communicated via tubing 261, T-piece128 and tubing 124 and 126 to the first and second vacuum inlet nozzles14, 114 to pull or draw air into the nozzles. The strength of thenegative pressure generated at the nozzles 14, 114 is regulated byincreasing or decreasing the motor speed of the compressor 234 by usingthe up and down arrows 60, 62 located on the external surface of thehousing 30 (see also FIG. 5). Increasing the motor speed of thecompressor 234 in this manner enables the compressor to achieve maximumor minimum vacuum exerted at the nozzles 14, 114. Thus, the degree ofmass air flow entering the first and second vacuum inlet nozzles 14,114, as well as the degree of mass air flow exiting open tubing 260 isregulated by adjusting the up and down buttons 60, 62. Adjusting thecompressor motor speed can thus be done with one hand by the user, andpermits the user to control the vacuum pressure at the first and secondvacuum inlet nozzles 14, 114 without the need for using a manual controlvalve 18 or recirculation circuit 203 (as seen in FIG. 2). Rather,buttons 60 and 62 perform this task, which are located on the face ofthe external surface of the housing 30 of the apparatus 200. Positivepressure is also created by the compressor 234 as gas or air is pumpedout of the pressure outlet 38, and is communicated out open tubing 260as an internal positive pressure outlet nozzle, to expel compressed airharmlessly within the inside of the housing 30. This allows excesspressure to be released, acts as a “bleed off” to control the vacuumcreated by the pump 234, and helps to regulate the amount of airexpelled into the housing. This in turn helps to regulate the amount ofvacuum that is produced.

FIG. 8 is a plan view of the interior electrical circuitry of theapparatus 200. Similarly to FIG. 4, the apparatus 200 of FIG. 12includes a battery 40 which provides electrical power to the aircompressor 234 via a circuit board 64. The circuit board 64 receivesenergy when turned “on” from the battery 40, receives input from theon/off button 13 and the up and down arrows 60, 62 of the apparatus, andalso connects to the conductivity indicator 174. Thus, when the on/offbutton 13 is placed in the “on” position, the circuit is completed andthe battery 40, the air compressor 234, the up and down buttons 60, 62and the conductivity indicator 174 are operational. Turning the on/offbutton 13 to the “off” position will break the circuit and theseportions of the apparatus 100 will turn off. For simplicity sake, theair pressure circuitry of FIGS. 6 and 7 is shown separately from theelectrical circuitry of FIG. 8; however, both of these circuitries areto be housed together within housing 30 of the apparatus 200.

As seen best in FIG. 5, the apparatus 200 is typically used inconjunction with an air pressure measuring device 24 such as amanometer. The conductivity indicator 174 is used to measure electricalresistance in ohms across the actuation switch of the pressure switch22. A lack of electrical current across this switch indicates that thereis not enough vacuum or air flow to complete the electrical circuitwithin the pressure switch, or that the pressure switch has failed.

The air compressor 234 within the apparatus 200 of FIGS. 5 and 8provides the vacuum production for the apparatus via nozzles 14 and 114,and the up and down buttons 60, 62 are used to regulate the amount ofvoltage transmitted via the control panel to the air compressor 234.Rather than the bypass control valve 18 and recirculation circuit 203(including 280A, 280B, 201, 202, 263) of prior art FIGS. 1 and 2, the upand down buttons 60 and 62 regulate the amount of air that can be drawnthrough the nozzles 14 and 114, and thus the pressure value of thevacuum. Being able to increase or decrease the vacuum strength by simplypressing the up and down buttons 60, 62 allows the user of the presentinvention to use a single hand to adjust airflow, as compared to theprevious embodiment of this invention in which two hands are typicallyrequired to hold the apparatus while adjusting the bypass control valve18. In the configuration shown in FIG. 5, the vacuum inlet nozzles 14,114 are connected into fluid communication with a vacuum port 42 of thepressure switch 22 (via tubing 26) and the manometer 24 (via tubing 27),respectively. The arrow buttons 60, 62 allow the user to easily preventundue stress on the air compressor by controlling the amount of air tobe pulled in from the vacuum port 42.

In use, the various embodiments of the apparatus of the invention can beused for calibrating an adjustable pressure switch. For example, lookingat FIG. 5, the apparatus 200 can be used to calibrate an adjustablepressure switch 22 which operates in a “normally open” manner. Thismeans that until a sufficient vacuum is measured across the pressureswitch 22, the electrical circuit is open and no electrical signal isgenerated. The adjustable pressure switch 22 has a set screw 44 which isused to activate or deactivate an electrical circuit when the targetpressure differential across the pressure-side port 45 and thevacuum-side port 42 is achieved. After assembling the circuitry, asillustrated in FIG. 5, the user adjusts the set screw 44 on theadjustable pressure switch 22 to be calibrated to “full open” so thatthere is little or no differential between the vacuum port 42 and thepressure port 45, and to completely open the switch 22 to thecalibration apparatus 200. The calibration apparatus 200 is then turned“on” by pushing button 13 to operate the air compressor 34, and the aircompressor 234 strength is slowly adjusted, via pushing either theincrease voltage button 60 or decrease voltage button, until thepressure reading on the manometer 24 matches the manufacturer'sspecified pressure (or vacuum) for the pressure switch 22. The user thenslowly adjusts the set screw 44 on the adjustable pressure switch 22until the conductivity indicator confirms that electricity is flowingacross the switch 22 and it has closed. At this point, the user slowlyadjusts the set screw 44 on the adjustable pressure switch 22 until theindicator confirms that the switch is open. At this point the pressureswitch is calibrated. In summary, then, if the indicator confirms thatthe switch is open, the user slowly adjusts the set screw on theadjustable pressure switch until the indicator confirms that the switchis closed, then slowly adjusts the set screw on the pressure switchuntil the indicator confirms that the switch is open. At this point thepressure switch is calibrated.

The apparatus of the present invention can also be used as a diagnostictool for early detection of pressure switch failure. That is, theapparatus can also be used to hold a specific pressure differential onany pressure switch, adjustable or not, thereby enabling diagnostictesting of the pressure switch. For example, to diagnose a pressureswitch failure for a “vacuum, normally open” pressure switch similar tothe previous example above, the apparatus 200 is first attached to thepressure switch 22 as explained above. Once the proper air pressure (orvacuum) is attained and the test leads 176, 178 of the conductivityindicator 174 are attached, the user slowly adjusts the increase voltagebutton 60 to increase the amount of vacuum pressure transmission to thepressure switch from the nozzle 14 until the pressure switch closes (asconfirmed by the conductivity indicator 174). If this closing pressureis not within the manufacturer's recommended specifications, then theswitch should be adjusted, and, if it is not adjustable, should beconsidered unsafe and should be replaced, regardless of whether thefurnace is presently operating properly or not.

Pressure switches that have had water in them are notorious for being a“sticking switch.” Water develops within pressure switches for a numberof reasons. High efficiency furnaces operate at lower temperatures thusresulting in condensation. Older furnaces were often operated at muchhigher temperatures, thus not allowing any condensation to form. Ifthere is a trap in the tubing (i.e. the line goes down then up) thatconnects the pressure switch to the furnace, the tubing may fill withwater. This in turn will shut the furnace down, but water in the tubingmay enter the pressure switch. Also, simply because the furnace iscausing condensation, water may enter the pressure switch. Condensationcontains contaminants which build up over time. If the pressure switchis made of metal it is further complicated because the water will causerust to form on the pressure switch, which will cause the pressureswitch to fail. If the pressure switch is sticking or is full of water,it should be replaced regardless of whether the furnace is presentlyoperating properly or not. To test for a sticking pressure switch,adjust the pressure a little beyond the specified settings, using thediagnostic method explained above. The switch will be inconsistent withclosing and opening if it is sticking. It also may be intermittent inoperating meaning it may close then open properly one time out of aboutthree to five trials.

By using the apparatus of the present invention one can also test for aruptured diaphragm in the pressure switch, as the switch will close andthen open shortly thereafter. This indicates that the diaphragm hasmoved and the switch closed because of the pressure, but if the pressurebleeds through the diaphragm, and the pressure remains constant, thediaphragm will move back and open the switch. To test this, once thecorrect pressure has been reached and the switch closes, wait 10 to 30seconds. If the switch remains closed then the diaphragm located insidethe switch is holding and is good. If the conductivity meter light goesout the switch has opened (on a normally closed switch), then there isleakage in the diaphragm. This switch should be replaced regardless ofwhether the furnace is presently operating properly or not.

FIGS. 9-12 illustrate another embodiment of the present invention whichincorporates both a manometer and a conductivity indicator within theinside of the housing of the calibration and diagnostic apparatus.Similar to the apparatus 200 in FIGS. 5-8, the apparatus 300 in FIG. 9includes an on/off button 13, a vacuum inlet nozzle 14, an “up” arrow orincrease voltage button 60, a “down” arrow or decrease voltage button62, conductivity indicator light 174, and conductivity indicator leadinputs 176 and 178 on the external surface of the housing 50. Theexternal surface of the housing 50 also includes a pressure measuringnozzle 214 (rather than the second vacuum inlet nozzle of FIGS. 4-8),and the front face of the housing 50 includes a pressure measuringdevice readout screen 70 (or a manometer readout screen 70). Pressuremeasuring nozzle 214 is connected to an internal pressure measuringdevice (or manometer 80, see FIG. 10). As illustrated in FIG. 9, thepressure measuring nozzle 214 and the vacuum inlet nozzle 14 can beremovably connected to a pressure switch 22 by way of flexible hose 126,T-Piece 226, and hoses 215 and 115. The pressure switch 22 can also beconnected to conductivity indicator leads 176 and 178 via electricaltest leads 132 and 133. When this circuit is completed, the conductivityindicator light 174 illuminates.

FIG. 10 illustrates a plan view of the internal air pressure circuitryof the apparatus 300 of FIG. 9. Specifically, FIG. 10 shows thecircuitry including the air compressor 234 having a vacuum inlet 36 anda pressure outlet 38. The vacuum inlet 36 is connected by flexibletubing 261 to the vacuum inlet nozzle 14. There is no positive pressureoutlet nozzle connecting the pressure outlet 38 to the outside, suchthat positive pressure [+] flows freely inside the housing, typicallyfrom flexible tubing 260 attached to the unused internal positivepressure outlet 38. The internal pressure measuring device or manometer80 connects via tubing 150 to the pressure measuring nozzle 214.

Viewing FIG. 10, when the air compressor 234 is in the “on” position,gas or air is drawn into the vacuum-side inlet 36, which reduces the airpressure on the vacuum-side connecting means 261, and the negativepressure created at the vacuum inlet 36 is communicated via tubing 261to the vacuum inlet nozzle 14 to pull or draw air into the nozzle.Likewise, positive pressure is created by the compressor 234 as gas orair is pumped out of the pressure outlet 38, and is communicated out theunused open tubing 260 as an internal positive pressure outlet nozzle,to expel compressed air harmlessly within the inside of the housing 50.This allows excess positive pressure to be released, and acts as a“bleed off” to control the vacuum created by the pump 234. The manometer80 measures the pressure of the gas that is communicated through thepressure measuring nozzle 214, which is typically connected externallyto nozzle 14 via a T-piece to measure the pressure transmitted from apressure switch (see FIG. 9). The pressure at the vacuum inlet nozzle 14is regulated by increasing or decreasing the amount of voltage beingsent to the compressor 234, via up and down buttons 60 and 62.Increasing the motor speed of the compressor in this manner enables thecompressor 234 to achieve maximum or minimum vacuum exerted at thevacuum inlet nozzle.

Thus, the degree of mass air flow entering the vacuum inlet nozzles 14,as well as the degree of mass air flow exiting open tubing 260 isregulated by adjusting the up and down buttons 60, 62. Adjusting thecompressor motor speed can typically be done with one hand by the user.A battery 40 provides electrical power to the air compressor 234 via acircuit board 64. The circuit board 364 receives input from the on/offbutton 13 and receives energy when turned “on” from the battery 40, andalso receives input from the up and down arrows 60, 62 in the housing 30of the apparatus, and also connects to the conductivity indicator 174.Thus, when the on/off button 13 is placed in the “on” position, thecircuit is completed and the battery 40, the air compressor 234, the upand down buttons 60, 62, the manometer screen 70, the conductivityindicator 174, and internal manometer 80 are operational. Although themanometer 80 is shown in front of the manometer screen 70 in FIGS. 10and 11, it can be appreciated that the manometer 80 is typically placedbehind the screen 70, and is illustrated in this way for understandingpurposes.

The circuit board of the apparatus of FIGS. 9-11 and 13-14 can also beprogrammed to allow a user to test a pressure switch in the followingmanner: the user presses the “on/off” button (which, when the apparatusis already in the “on” position, is programmed to act as a “hold” or“capture” button), then presses and holds the “up” arrow. The pumpoutput increases rapidly, and the moment the switch closes, the pressurevalue is captured by the manometer (this is programmed into the circuitboard). The user notes the reading, then presses the “hold” (i.e.“on/off”) button again to release the captured reading. The user thenpresses the “hold” button once again, and then presses and holds the“down” arrow. The pump output decreases rapidly, and the moment theswitch opens, that pressure value is also captured by the manometer. Theuser then notes the readings.

The circuit board can also be programmed so that the user can simplyconnect the apparatus to the pressure switch to be tested, press the“on/off” button (after the apparatus has already been turned “on”) andthe apparatus does the above automatically. Further, it can beappreciated that while the “on/off” button can be programmed to performthese functions, it would be an easy task to add separate “hold” or“capture” buttons to the apparatus in order to separately control thepressure measuring functions of the apparatus, rather than using the“on/off” button to do so.

FIG. 11 is a plan view of the interior electrical circuitry of theapparatus 300. In use, when the on/off button 13 is placed in the “on”position, the circuit within the circuit board 364 is completed and thebattery 40, the air compressor 234, the up and down buttons 60, 62, themanometer 80, manometer screen 70, and the conductivity indicator 174(conductivity can also be displayed on the manometer screen) areoperational. Turning the on/off button 13 to the “off” position willbreak the circuit and these portions of the apparatus 300 will turn off.Conductivity indicator lead inputs 176 and 178 are connected to thecircuit board 364, which is connected to the conductivity indicatorlight 174 (or indicated on the manometer screen). Thus, the conductivityindicator light 174 will be activated upon completion of the circuitbetween lead input 176 and lead input 178. Therefore, this apparatus canbe used solely as a conductivity indicator, exclusive of its ability totest pressure switches. This is true as well for the pressure measuringdevice. For example, if the pressure switch is a normally open switch,the conductivity indicator light 174 will illuminate if the switch isworking properly. Most pressure switches with two ports on them have a“common” terminal (in the power source) a “normally open” terminal(which closes once the pressure reaches the operating setting), and a“normally closed” terminal (which opens once the pressure reaches thesetting or prevents the furnace from starting if it is open). Forsimplicity sake the air pressure circuitry of FIG. 10 is shownseparately from the electrical circuitry of FIG. 11; however, both ofthese circuitries are to be housed together within the apparatus 300.

The apparatus 300 of FIGS. 9-11 is used in a similar manner as explainedabove for the apparatus 200 of FIGS. 5-8; however, manometer screen 70is also incorporated within the housing 50, and manometer 80 is includedinside of the apparatus 300. This allows the user to convenientlycalibrate and test the function of a pressure switch with a singleapparatus, without having to carry or provide a separate pressuremeasuring device.

The device of the present invention is generally able to detectpressures between negative (−) 20.00 to positive (+) 20.00 inches ofwater, and more typically between negative (−) 10.00 and negative (−)0.20 inches of water. However, if an external bleed port is used,pressures at negative (−) 0.01 inches of water can be measured. Also,while the upper limit of pressures measured is typically 20 inches ofwater for regular purposes, depending on the strength of the aircompressor used in the apparatus, larger positive pressures up to 200inches of water can also be measured using the apparatus of theinvention. FIG. 12 shows a variation of the connection between theapparatus 300 of FIG. 9 and the pressure switch 22, showing an externalbleed port 231 that can be added for achieving lower pressures. Tubing116 and T-piece 230 is added between the vacuum inlet nozzle 14 andtubing 115. Opening 231 of the T-piece 230 is left open to air, whichprovides a bleed port for vacuum pressure to escape, and allows the userto measure pressures as low as 0.1 inches of water. The external bleedport is used to help regulate and maintain pressures from negative (−)0.01 inches of water to positive (+) 0.20 inches of water column. It isincorporated into the device to also test pressure switches that do nothave an internal bleed port.

With reference to FIGS. 13 and 14, another embodiment of the pressureswitch calibration and diagnostic device 400 of the present invention isillustrated, which includes a pressure measuring nozzle 214 and apositive pressure outlet nozzle 216 in addition to the vacuum inletnozzle 14 on the external surface of the housing 55, and alsoincorporates a manometer 80 inside the housing 55 of the calibration anddiagnostic apparatus 400. Similar to the apparatus 300 in FIGS. 9-11,the apparatus 400 includes an on/off button 13 in the front face of thehousing, a manometer readout screen 70, an “up” arrow or increasevoltage button 60, a “down” arrow or decrease voltage button 62, aconductivity indicator light 174, and conductivity indicator lead inputs176 and 178 on the external surface of the housing 55. While FIGS. 9-11and 13-14 show the indicator light 174, it can be appreciated that,because of the use of a circuit board, the indicator light can beeliminated and incorporated on the readout of the manometer screen 70.The internal air pressure circuitry of the apparatus 400 includes an aircompressor 234 having vacuum inlet 36 and pressure outlet 38. The vacuuminlet 36 is connected by flexible tubing 261 to the vacuum inlet nozzle14. The pressure outlet 38 is connected by flexible tubing 262 to thepositive pressure outlet nozzle 216. An internal pressure measuringdevice or manometer 80 connects via tubing 150 to the pressure measuringnozzle 214.

When the air compressor 234 is in the “on” position, gas or air is drawninto the vacuum-side inlet 36, which reduces the air pressure on thevacuum-side connecting means 261, and a vacuum is created andcommunicated via tubing 261 to the vacuum inlet nozzle 14 to pull ordraw air into the nozzle. Likewise, positive pressure is created by thecompressor 234 as gas or air is pumped out of the pressure outlet 38,which is communicated via tubing 262 to positive pressure outlet nozzle216. The manometer 80 measures the pressure of the gas that iscommunicated through the pressure measuring nozzle 214, which istypically used to measure the pressure transmitted from a pressureswitch (e.g. see FIG. 9). The pressure at the vacuum inlet nozzle 14 isregulated by increasing or decreasing the amount of voltage being sentto the compressor 234, via up and down buttons 60 and 62. Increasing themotor speed of the compressor in this manner enables the compressor 234to achieve maximum or minimum vacuum exerted at the vacuum inlet nozzle14. Thus, the degree of mass air flow entering the vacuum inlet nozzle14, as well as the degree of mass air flow exiting positive pressureoutlet nozzle 216 is regulated by adjusting the up and down buttons 60,62. Adjusting the compressor motor speed in this manner can typically bedone with one hand by the user.

As shown in FIG. 14, a circuit board 364 receives input from the on/offbutton 13 and the up and down arrows 60, 62, and also connects to (andthus provides power to, via the battery 40) the manometer screen 70, theconductivity indicator 174, and internal manometer 80. Although themanometer 80 is shown in front of the manometer screen 70 in FIGS. 13and 14, it can be appreciated that the manometer 80 is typically placedbehind the screen 70, and is illustrated in this way for understandingpurposes.

In use, when the on/off button 13 is placed in the “on” position, thecircuit within the circuit board 364 is completed and the battery 40,the air compressor 234, the up and down buttons 60, 62, the manometer80, manometer screen 70, and the conductivity indicator 174 areoperational. Turning the on/off button 13 to the “off” position willbreak the circuit and these portions of the apparatus 300 will turn off.Conductivity indicator lead inputs 176 and 178 are connected to thecircuit board 364, which is connected to the conductivity indicatorlight 174. Thus, the conductivity indicator light 174 will be activatedupon completion of the circuit between lead input 176 and lead input178. Therefore, this apparatus can be used solely as a conductivityindicator, exclusive of its ability to test pressure switches. This istrue as well for the pressure measuring device.

The embodiments shown in FIGS. 9-12 and FIGS. 13-14 can also include asecond internal pressure measuring device or manometer (not shown),similar to manometer 80. The second manometer can connect via tubing toa second pressure measuring nozzle (similar to nozzle 214) on theexternal surface of the housing of the apparatus, exiting next topressure measuring nozzle 214. This port could also be used to measurepositive or negative gas pressure. The second pressure measuring deviceis in fluid communication with the second pressure measuring nozzle, andin electrical communication with the circuit board 364 and the pressurereadout screen 70. Dual pressure switches are also used to set the gaspressure of the gas valve in high efficiency units. When the gas ignitesthere is a slight variance in the pressures measured by a manometer. Thegas pressure is then adjusted to the manufacturer's specifications.

In the embodiments shown in FIGS. 5-14, the battery 40 is typicallyeither a single 9 Volt battery or two size AA batteries, but can be anytype of device that can store and provide electrical power to theapparatus. Also, it is to be noted that the apparatus is not limited tousing a single battery; the manometer 80 and the air compressor 234 canbe wired to run off of separate batteries as well.

The portable calibration apparatus of the present invention is typicallyable to diagnose problems with any manufacturer's HVAC pressure switch,and will also be able to calibrate any adjustable pressure switch.Adjustable pressure switches typically include both a pressure port anda vacuum port and can be used in place of the manufacturer's pressureswitch, should a service technician not have an exact replacement switchat the worksite. Further, the apparatus can be used to diagnose problemswith pressure signal transducers. A signal transducer is like anelectronic version of the pressure switch. In the newer furnaces signaltransducers are used with or used in conjunction with a pressure switch.Similar to the pressure switch, it completes or opens a circuit if thepressure is incorrect. Pressure is measured electronically, eliminatingthe need for a mechanical device. A more precise measurement is thusable to be measured by signal transducers.

The various embodiments of the portable calibration apparatus disclosedherein are typically intended to be light in weight and small enough tofit in one hand of the technician, to be carried from one work site tothe next in a pocket or small carrying bag. Early detection of pressureswitch failure while the pressure switch is incorporated into an HVACsystem has previously not been this easy to perform. The variousembodiments of the apparatus of the present invention can potentiallydecrease the number of return visits currently made by HVAC servicetechnicians, reduce overtime costs, and will likely prevent propertydamage caused by incorrect pressure switch settings and/or previouslyunrecognized pressure switch failure. The pocket sized apparatus isconveniently held and operated by one hand, making it extremely suitablefor HVAC service technicians. A technician will no longer have to carrylarge calibrating devices to the worksite, or alternatively be resignedto replacing a properly functioning pressure switch because propertesting equipment is not available.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not intended to restrict or in any way limitthe scope of the appended claims to such detail. Additional advantagesand modifications will be readily apparent to those skilled in the art.Accordingly, departures may be made from such details without departingfrom the scope of the invention.

What is claimed is:
 1. An apparatus for calibrating and testing apressure switch, the apparatus comprising: a) a housing including aninside and an external surface; b) an air compressor located on theinside of the housing, the air compressor including a vacuum-side inletand a pressure-side outlet; c) a first vacuum inlet nozzle in fluidcommunication with the vacuum-side inlet of the air compressor, thefirst vacuum inlet nozzle being located on the external surface of thehousing; d) a second vacuum inlet nozzle in fluid communication with thevacuum-side inlet of the air compressor, the second vacuum inlet nozzlebeing located in the external surface of the housing; e) a positivepressure outlet nozzle in fluid communication with the pressure-sideoutlet of the air compressor, wherein the positive pressure outletnozzle is located inside the housing of the apparatus; f) a circuitboard located on the inside of the housing; g) a battery located on theinside of the housing for supplying power to the circuit board; h) anincrease voltage button located on the external surface of the housingand in electrical communication with the circuit board, whereinactivating the increase voltage button will cause the circuit board toincrease the voltage supplied to the compressor; i) a decrease voltagebutton located on the external surface of the housing and in electricalcommunication with the circuit board, wherein activating the decreasevoltage button will cause the circuit board to decrease the voltagesupplied to the compressor; j) a pair of conductivity indicator leadinputs located on the external surface of the housing and in electricalcommunication with the circuit board; k) a conductivity indicator lightlocated on the external surface of the housing and in electricalcommunication with the circuit board, wherein the conductivity indicatorlight is operable to visually indicate whether the pressure switch isopen or closed; and l) an on/off button located on the external surfaceof the housing for completing an electrical circuit between the batteryand the circuit board, wherein when the on/off button is placed in the“on” position, the circuit is completed and the battery, the aircompressor, the increase and decrease voltage buttons, and theconductivity indicator light are operational.